INSTALLATION INSTRUCTIONS
SPOOLING INSTRUCTIONS
6. Once rope loop is pulled through pocket, unwind installation wire and remove completely. Be careful not to harm the rope. .
10. Reconnect negative cable to the battery that is used to power the winch. WARNING Always wind the winch rope on bottom (mount side) of drum. WARNING Never operate winch with less than 10 wraps of winch rope around the drum. Rope could come loose from the drum, as the winch rope attachment to the drum is not designed to hold a load. WARNING Never touch winch rope or hook while someone else is at the control switch or during winching operation. 11. Turn the clutch lever on the winch to the “Engaged” position. 12. Wind 10 wraps of rope onto the drum while applying light tension on the rope.
disengaged the drum is in the freespool position and the gear train and winch rope drum are uncoupled allowing the drum to rotate freely. The clutch lever, located on the winch housing opposite the motor, controls the clutch position. To prevent damage, always fully engage or fully disengage the clutch lever. Rope Spooling Instructions: THE FOLLOWING STEPS ARE VERY IMPORTANT AND IF NOT PRECISELY FOLLOWED THE LIFE OF THE WINCH AND ROPE MAY BE COMPROMISED. 1. Choose a FLAT AND LEVEL location that is large enough to run out almost the entire length of winch rope. 2. Disengage clutch. NOTE: See your product’s specific operation manual for detailed clutch operation. WARNING Always keep hands clear of winch rope, hook loop, hook and fairlead opening during installation, operation, and when spooling in or out. 3. Grasp hook strap and spool out the winch rope to the last 5 wraps on the drum (10 wraps if synthetic rope). 4. Once the winch rope is spooled out, engage clutch. NOTE: See your product’s specific operation manual for detailed clutch operation instructions. 5. Attach the hook end of the rope to a suitable anchor point. WARNING Always be certain the anchor you select will withstand the load and the strap or chain will not slip. 6. Return to your vehicle. 7. Back the vehicle away from the anchor point until there is very little slack in the winch rope. 8. Set the parking brake, place the vehicle in gear or park and turn the vehicle off. WARNING Always stand clear of winch rope and load and keep others away while winching. 9. Exit vehicle. WARNING! Never exit the vehicle with a load on the winch rope. While standing approximately 8 ft. (2.44 m) away from the winch, power-in the winch until all of the slack is wound onto the winch drum. WARNING Never touch winch rope or hook while someone else is at the control switch or during winching operation. WARNING Never touch winch rope or hook while under tension or under load. 10. With gloves on, hold tension on the winch rope
with one hand; carefully push the winch rope to the side of the drum the winch rope is attached to so there are no gaps between each coil on the drum. WARNING Always wind the winch rope on bottom (mountside) of drum. 11. Be sure to check that the winch rope is winding off of the bottom of the drum or the automatic load holding brake will not function properly. NOTE: If the winch rope is winding off the top of the drum, you have powered the winch “out” instead of “in” on the remote control. Be sure you are powering in. 12. The following steps should be done using two people for proper safety. If you attempt to tension your winch rope alone be sure to always set the parking brake, place the transmission in gear or park and turn the vehicle off every time you exit the vehicle to inspect the winch rope. NOTICE Use care to evenly wrap each layer to prevent damage to the rope. WARNING Never use remote when vehicle is not in line of sight of operator. 13. The driver of the vehicle should operate the winch. 14. Instruct your assistant to stand to the side of the vehicle and away from the winch rope. NOTE: Your assistant should signal you if the winch rope is winding correctly or incorrectly by watching it move across the fairlead as the winch rope is powered in. 15. Start the vehicle and place the transmission in neutral. Then release the parking brake while applying moderate brake pedal pressure. 16. Power-in the winch rope to start winching in. 17. After winching in for approximately 6 ft. (2m), stop winching. 18. Slowly let up off of the brake pedal and then apply the parking brake. This will ensure that there is no load on the winch rope. 19. Place the transmission in park or in gear and turn the vehicle off. 20 Exit the vehicle and inspect the winch to make sure that the winch rope is being evenly wound onto the winch drum and not sinking into the lower layer. If the winch rope is sinking, power- out the winch rope by pushing the power-out button on the remote control and repeat this step from the beginning with more brake pedal pressure. 21. When you are convinced the winch rope is
7. Install the 5/16” rope puck in the center of the rope eyelet.
System Check Once you have performed a system check, you are ready to confirm winch function. Proceed to First Time Operation Instructions and Final Analysis and Maintenance sections in this booklet. First Time Operating Instructions In this section, we’ll show you the first time operating instructions for effective basic winching. For complete winch operation and techniques read the Basic Guide to Winching Techniques found online at http://www. warn.com. Remote Control The winch is controlled by the hand held remote control. The remote control provides control of the power-out (forward) or power-in (reverse) rotation of the spooling drum. Do not leave the remote plugged into the winch when not in use. Leaving the remote plugged in, may result in a dangerous condition and/or battery drain. Clutch Operation: WARNING Never engage or disengage clutch if winch is under load, winch rope is in tension or drum is moving. When the clutch is engaged, the gear train is coupled to the winch drum and power can be transferred from the winch motor. When the clutch is
8. Keep the puck in place while slowly pulling the rope away from the drum. Once the puck is seated against the rope on all sides, pull the rope way from the drum until the puck lodges with the rope into position.
9. Ensure the loop does not protrude from the drum surface and that the rope is held into place tightly.
WARN INDUSTRIES 9
WARN INDUSTRIES 10
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